Multi-Material Boss Structure for Durable Die-Cast Fastening
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Solution Overview
Problem
Existing die cast parts with bosses experience fastening failure and decreased effectiveness due to wear-and-tear from assembly and disassembly, particularly when using screws, and replacing bosses with threaded inserts or bushings increases costs.
Innovation Solution
A multi-material boss comprising a boss cylinder made of the same material as the die cast part, an augmenting cylinder with higher hardness and liquidus temperature, and a filler metal layer, which is bonded and shaped to provide enhanced fastening capabilities without the need for pre-threaded parts or additional adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If threaded inserts or bushings are used to replace bosses, then fastening strength and durability are improved, but manufacturing cost increases due to pre-threaded parts and additional adhesives
Solution Approach 1:
The patent merges the boss and the threaded insert into a single integrated component. The threaded insert is formed directly within the boss cavity during the die-casting process, eliminating the need for separate pre-threaded parts and adhesives. This integration maintains high fastening strength while reducing manufacturing complexity and cost.
Solution Approach 2:
The threading structure is preliminarily formed within the boss cavity before the final fastening operation. By creating the threaded insert in advance during die-casting, the patent eliminates the need for subsequent threading operations or adhesive application, streamlining the manufacturing process.
2Reliability
If threaded inserts or bushings are used to replace bosses, then fastening reliability is improved, but device complexity increases due to additional components and assembly steps
Solution Approach 1:
The patent combines multiple functions (structural support, threading, and fastening) into a single integrated boss component. This merger reduces the number of separate parts and assembly steps, thereby lowering device complexity while maintaining the reliability benefits of threaded fastening.
3Productivity
If die casting is used to manufacture bosses, then productivity is improved, but fastening strength decreases due to material density and hardness limitations
Solution Approach 1:
The patent creates a composite structure where a threaded insert (made of metal or alloy with superior strength properties) is formed within the die-cast boss. This composite approach combines the high productivity of die-casting with the high strength of metal threading, achieving both manufacturing efficiency and fastening strength.
Solution Approach 2:
The patent applies local quality enhancement by concentrating the high-strength material specifically in the threaded insert region where fastening strength is critical, while the rest of the boss can remain as standard die-cast material. This localized strengthening maintains overall productivity while addressing the specific weakness at the fastening point.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The multi-material boss provides improved fastening strength and stability, reducing the risk of failure while maintaining cost-effectiveness by eliminating the need for pre-threaded parts and adhesives, and facilitating efficient bonding through venting and capillary action.
Implementation Method 1
The filler metal layer is made of a material having a third liquidus temperature lower than that of the first and second liquidus temperatures, at least partially compressed between the base rim of the augmenting cylinder and first base of the interior of the boss cylinder
Implementation Method 2
The filler metal layer is made of a material having a third liquidus temperature lower than that of the first and second liquidus temperatures
Implementation Method 3
facilitating efficient bonding through venting and capillary action
Implementation Method 4
The augmenting cylinder is made of an augmenting material having a second liquidus temperature and a second hardness, is fixedly secured in the first interior of the boss cylinder
Data Source
AI summary
A multi-material boss, configured for fastening of a fastener thereto, being a feature of a die cast part, comprising a boss cylinder, an augmenting cylinder, and a filler metal layer is provided. The boss cylinder is made of the same material as the die cast part having a first hardness, and has a first interior. The augmenting cylinder is made of an augmenting material having a second hardness, is fixedly secured in the first interior of the boss cylinder, and has a second interior defined by a second cylindrical shaped wall, a base rim, and a second opening. The second hardness is greater than the first hardness. The fastener is fastened to the multi-material boss via the second opening of the augmenting cylinder having the higher liquidus temperature and greater hardness.